On-site systems and methods for treating spent oxidizable catalyst in inert gas environments

ABSTRACT

A system for segregating a mixture of oxidizable catalyst material and inert support media. The system comprises an enclosure configured to contain inert gas. The enclosure includes a plurality of stacked screens disposed therein. The stacked screens include openings that decrease in size from a top of the stack to a bottom of the stack. The enclosure also includes an inlet to deliver the mixture to an uppermost stacked screen and outlets to direct the separated support media and catalyst material to a location outside the enclosure.

TECHNOLOGICAL FIELD

The present disclosure generally relates to the field of petroleumrefinement, and particularly relates to systems and methods forseparating refinery byproducts into hazardous and non-hazardouscomponents.

BACKGROUND

The petrochemical refinement industry is constantly searching for waysto improve upon refinery efficiency and cost savings. One avenue forachieving these goals takes place at the front end of the refinementprocess through refinery material selection. Generally, a combination ofcatalysts, inert support balls, and grading material (also referred toas topping or trap material) are selected. These materials are loadedinto one or more refinery unit vessels in accordance with a loading planwhich specifies the quantity and distribution of the materials in thevessels. The particular type of catalyst chosen depends on the desiredproduct (e.g. diesel, jet fuel, or kerosene) and catalyst performance(dictated by expected catalyst lifetime, raw material, desired finishproduct specifications, and other variables affecting the rate at whichthe catalyst is consumed). Topping is selected based on the desiredapplication (e.g., hydrotreating, hydrogenation, hydrydrocracking, lubeoils, or wax), and inert support balls are generally made of alumina,ceramic or silica.

In use, the inert support balls are loaded into the bottom of the vesselfollowed by a layer of catalyst (catalyst bed). Layers of inert supportballs and catalyst may be deposited in an alternating fashion until, forexample, 1-10 layers of catalyst may be deposited with interveninglayers of inert support balls. The inert support balls help to evenlydistribute raw petrochemical material and synthesized refined productacross the catalyst bed. Finally, grading material may be loaded on topof the layers to “trap” or remove impurities such as vanadium, nickel,or arsenic from the raw material. This grading material may be comprisedof a single material or various materials, each configured totrap/remove a particular impurity. The catalyst converts the rawmaterial into the refined product. This reaction ultimately causescatalyst activity and pressure within the refinery unit to decrease.

In order to efficiently process additional raw materials, the mixture ofcatalyst, inert support balls and grading are changed out once the unitpressure and/or catalyst activity fall below a predetermined threshold.During this process, inert gas (often nitrogen) is forced into one ormore vessels of the refinery unit to purge any remaining raw materialand liquid product. This purge leaves only the catalyst, topping andinert support (collectively known as industrial waste) behind. The dayon which this change occurs is commonly known in industry as the “oilout” date and may be predicted using unit performance indicators and rawmaterial specifications. Data relating to a previous oil out date mayalso be used to predict the next oil out date. A target oil out date isset well in advance (often 18-24 months) to account for replacementcatalyst manufacture time. The vessel is allowed to cool down (e.g. to300° F.) and the remaining catalyst, topping and inert support balls areextracted. Refineries generally replace all of the catalyst within aunit at the same time to take advantage of the “unit down time” and cutcosts.

Generally, extraction involves a “gravity dump,” during which thecatalyst, topping and inert support are permitted to fall through avalve in the bottom of the vessel. The material feeds into a pipe, whichleads to flow bins or the desired packaging for holding and transportingthe material. The rate at which the material enters the flow bins isgenerally regulated manually by a valve. Since each flow bin only holdsabout 1-2.5 tons, this process is repeated (5-500 times depending on thesize of the vessel) until the vessel is empty. A vacuum may be used asan alternative to the gravity dump, in which case, material is vacuumedthrough the top of the vessel and into the flow bins or other packagingof choice.

Once the materials are extracted, the vessels are refilled, and the flowbins (or packaging of choice) are directed to a holding area, where theyawait inventory, sampling, and profile generation for the destinationprocess facility. The Environmental Protection Agency categorizes spentcatalyst and topping as “hazardous waste” (e.g. K171 or K172);therefore, certain disposal guidelines must be followed. Three disposalmethods: are common in industry. One such method involves reclamation.During reclamation, the waste is “roasted” to render the hazardousmaterials inert, then processed using leaching or pyro-metallurgicaltechniques to extract metals, e.g., vanadium pentoxide, nickel, andmolybdenum from the materials. Another method of disposal involves“regeneration.” During regeneration, the waste is carefully roasted sothat a percentage of the spent catalyst may be re-introduced into therefining process. Yet another method of disposal sends roasted waste tolandfill. More recently, refineries have the option to send their wastematerials to cement kilns for alumina and energy reclamation. Sincekilns process liquids more easily than solids, the catalyst may betransformed into a slurry to facilitate processing. These catalystparticles fall out of the slurry suspension, clogging pipes anddisrupting the overall process.

Although inert support is generally classified as non-hazardous (in someinstances classified as hazardous) and account for up to 25% of refinerywaste, many refineries incur the same cost/pound for processing,packaging, and transporting non-hazardous waste as they do for hazardouswaste. This is because refineries do not separate the materials intohazardous and non-hazardous components prior to disposal. Thisunnecessary expense is often compounded by the cost of internationalshipping. Available options for separating the materials areinsufficient as they still require the refinery to continue to shipwaste offsite resulting in additional cost.

The systems and methods described herein address at least some of thedrawbacks of traditional industrial waste disposal by simplifying andmobilizing the industrial waste segregation process. Such systems andmethods may allow refineries to reduce the premium on hazardous wastemanagement and the amount of reportable hazardous waste.

SUMMARY

The present disclosure provides methods and systems for efficientlysegregating hazardous topping and catalyst material from inert supportmedia. Although reference is made to hazardous catalyst and toppingmaterial, it is to be understood that systems and methods disclosedherein may be used to separate hazardous materials from other hazardousmaterials and non-hazardous materials from other non-hazardousmaterials.

A first aspect of the disclosure provides a system for segregating amixture of oxidizable catalyst material and inert support media. Thesystem may include an enclosure configured to contain inert gas and aplurality of stacked screens disposed within the enclosure. The stackedscreens may include openings that decrease in size from a top of thestack to a bottom of the stack. The enclosure may include a mixtureinlet positioned to enable delivery of the mixture to an uppermoststacked screen. The system may further comprise at least one motor formoving the stacked screens to cause the oxidizable catalyst material toseparate from and migrate to a location beneath the inert support media;at least one inert support media outlet associated with at least one ofthe plurality of stacked screens and for conveying the separated inertsupport media to a location outside the enclosure; a catalyst materialoutlet associated with at least another of the plurality of stackedscreens for conveying the separated oxidizable catalyst material to alocation outside the enclosure; and an inert gas inlet associated withthe enclosure for conveying the inert gas to the enclosure. The inertgas displaces oxygen within the enclosure to thereby limit oxidation ofthe oxidizable catalyst while the at least one motor moves the pluralityof stacked screens.

Another aspect of the disclosure provides a method for disposing amixture of oxidizable catalyst material and inert support media. Themethod may include introducing inert gas into an enclosure; introducingthe mixture into the enclosure; separating the oxidizable catalystmaterial and the inert support media within the enclosure; maintainingan inert gas environment around the oxidizable catalyst material duringseparating; exporting the separated inert support media from theenclosure; and grinding the separated oxidizable catalyst material intoa powder for disposal as hazardous waste via incineration.

Yet another aspect of the disclosure provides a method for disposing ofa mixture of oxidizable catalyst material and inert support media. Themethod may include introducing inert gas into an enclosure, wherein theenclosure contains a plurality of stacked screens having openings thatdecrease in size from a top of the stack to a bottom of the stack;introducing the mixture to an uppermost one of the plurality of stackedscreens; moving the plurality of stacked screens to cause the oxidizablecatalyst material to separate from and migrate to a location beneath theinert support media; conveying the separated inert support media to alocation outside the enclosure for disposal as non-hazardous waste; andconveying the separated oxidizable catalyst material to a locationoutside the enclosure for at least one of reclamation, thermaldestruction, thermal processing, regeneration and/or disposal in alandfill.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this disclosure, illustrate various disclosed embodiments. Inthe drawings:

FIG. 1 is a perspective view of a system for segregating a mixture ofoxidizable catalyst material and inert support media in accordance withembodiments of this disclosure.

FIG. 2 is a partial cut-away view of the assembly depicted in FIG. 1 .

FIG. 3A is a detailed view of the screen assembly illustrated in FIG. 1.

FIG. 3B is a partial cut-away view of the screen assembly illustrated inFIG. 3A.

FIG. 4 is a block diagram of a first exemplary process in accordancewith embodiments of this disclosure.

FIG. 5 is a block diagram of a second exemplary process in accordancewith embodiments of this disclosure.

FIG. 6 is a block diagram of another exemplary process in accordancewith embodiments of this disclosure.

DETAILED DESCRIPTION

The following detailed description refers to the accompanying drawings.Wherever possible, the same reference numbers are used in the drawingsand the following description to refer to the same or similar parts.While several illustrative embodiments are described herein,modifications, adaptations and other implementations are possible. Forexample, substitutions, additions, or modifications may be made to thecomponents illustrated in the drawings, and the illustrative methodsdescribed herein may be modified by substituting, reordering, removing,or adding steps to the disclosed methods. Accordingly, the followingdetailed description is not limited to the disclosed embodiments andexamples. Instead, the proper scope is defined by the appended claims.

Some embodiments of this disclosure may involve systems and methods forsegregating materials in a mixture. Although embodiments of the currentdisclosure may be used to segregate (or separate) one or moreconstituent materials of any type of mixture, in the discussion thatfollows, an exemplary embodiment of segregating or separatingconstituent materials of industrial waste is described. Industrial wastefor example, may include petrochemical refinement waste, which whileclassified as hazardous, may be made up of both hazardous andnon-hazardous components. The non-hazardous components may include aninert material, such as inert support media made of, by way of example,alumina, ceramic or silica. The hazardous components may include anoxidizable catalyst and grading material. Together, these components mayform a mixture. If the catalyst can be separated from the inertmaterials, the inert materials can be sold, recycled, or disposed of asnon-hazardous waste, reducing the overall disposal cost. Moreover, insome instances, the catalyst, if separated from the inert materials,might be reclaimed and reused, lowering overall processing costs. Inother instances, the catalyst may be disposed of, such as throughincineration.

The term “catalyst” as used herein refers includes any of a variety ofcatalyst materials that are used in the refinement of oil, including butnot limited to those listed in Table 1 below. It should be noted thatthe materials listed in the table are only exemplary, and in general,the catalyst may include any currently used or later developed catalystmaterial.

TABLE 1 Z-863 TL TK-550 NK-621 ICR 179 LAQ HOP-603K CatTrap 10 (1.6)Z-853 TL TK-527 NDXi ICR 178NAQ HOP492K C-411 (2.5) Z-853 TL TK-47 N-2051.5Q ICR 168NAQ HC-80 AT792 (1.6) Z-803 TL TK-453 MaxTrap (Ni,V) ICR 160LAQ HC-53LT AT775 (1.6) VGO Z-753 CY TK 45 MaxTrap (Ni,V) ICR 154NAQHC-26L AT724G (2-8) Z-753 CY TK-439 MaxTrap (As) ICR 141N84 HC-24L AT580(1.6) Z-503 TL TK-437 LK-823 ICR 141LY8 HC-150LT AT575 (2.5) Z-503 TLTK-431 LK-821-2 ICR 141LY4 HC-120LT AT535 (1.3) UF-210 TK-341 LK-813 ICR141LY2 GSK-9 AT514 TK-951 TK-339 LK-811 ICR 141LW8 GSK-6A AT510 TK-943TK-30 KG-6-3Q ICR 141LW4 GSK-19 AT505 (All Sizes) TK-941 TK-261 KG-55ICR 141LW2 GN-863 TL (2.5) AT505 TK-931 TK-250 KG-5-2Q/3Q ICR 141LAQGC-862 TL (2.5) AT405 1/10″ TK-928 TK-25 Top Trap KG-1-5B ICR 141LW8 DN3551 TL 1.3 AT405 TK-926 TK-224 KF-905 ICR 141LW4 DN-3531 TL ASCENT DC-2531 TK-925 TK-222 KF-902 ICR 141LW2 DN-3310 TL AR-401, 11 × 6 TK-915TK-220 KF-901-3Q ICR 141LAQ DN-3300 TL AR-301, 4.5 × 4.5 TK-911 TK-15KF-9011.5E ICR 139Q01 DN-3120 TL AFS-1050 TK-907 TK-10 KF-859-2Q ICR 139Q01 DN-3110 TL AFS-1025 TK-831 support KF-859-1.50 ICR 132NAQ DN-3100 TLAFS-1010 TK-799 SK-201-A KF-857 ICR 122ZSF DN-200 TL ADS-120 TK-797SK-201 -2 KF-848-2Q ICR 122ZSB DN-200 ACT-989 TK-773 RN-412 TL (2.5)KF-848-1.3Q ICR 122 ZSB DN-140 TL ACT-951 TK-753 RM 412 TL (1.3)KF-846-3Q ICR 114(All DN-140 ACT-931 Sizes) TK-743 RN-412 KF-846-1.3QICR 114 NAQ DHC-39LT ACT-070 (inert) TK733 RM-5030 TL (5.6) KF-844 ICD132 NAQ DD-431 ACT-068 (inert) TK-719 RM-5030 TL (2.5) KF-843 HTZ-5DC-2551 1.3 834 HC (8.0) TK-711 RM-5030 TL (1.6) KF-841-3Q HTZ-3 DC-2533834 HC-8 TK-710 RM-5030 TL (1.3) KF-841-1.5Q HT-86TL DC-2532 815 HC(6.4) TK-709 RM-5030 KF-840-3Q HT-80R DC-2531 TL 815 HC (4.8) TK-607RKS-5-7H, 16 × 11 KF-767 HT-428 DC-2318 TL 815 HC-6.4 TK-605 RKNGR, 4.5× 4.5 KF-757-3Q HR-945 DC-2118 TL 815 HC-4.8 BRIM TK-576 RK-212, 16 × 11KF-757-1.5E HR-845 DC-130 814 HC BRIM TK-575 RK212 KF-756 HR-841 CR-55720X BRIM TK-574 RK-211, 16 × 1 KF-752 HR-806S CENTINEL GOLD 534 SH(8.0) DN-3330 TK-573 RK-202, 16 × 11 KF-648-3Q HR-626 CENTINEL GOLD 534SH (4.0) DN-3310 TK-570 RK-202 KF-648-1.3Q HR-568 CENTINEL GOLD 514 SHBRIM DN-3300 TK-565 RK-201 16 × 11 KF-647-3Q HR 538 CENTINEL GOLD 234 TL(3.2) DC-2318 TK-562 RK-201 KF-647-L3Q HR-448 CENTINEL DN-3120 855TK-561 R67-7H, 16 × 11 KF-542-5R/9R HR-426 CENTINEL DN-3110 834 BRIMTK-561 R-67-7H KF-542-5Q HR-416 CENTINEL DN-3100 815 TK-560 PK-7RKF-124LD HR 468 CENTINEL DC-2118 534 TK-559 OptiTrap 855 MD InterLayerHOP-802K CDXi 465 BRIM (CoMo) TK-558 OptiTrap (Ring) HC ICR 210L HOP-802CDX 234 BRIM 6.4 TK-554+ OptiTrap (Ring) ICR 210 L HOP-608K CatTrap 65TK-553 OptiTrap ICR 179(All HOP-606HK CatTrap 50 (Medallion) Sizes)TK-551 OptiTrap ICR 179 NAQ HOP-606H CatTrap 30 (MacroRing)

The term “segregating,” as used herein, refers to separating (or to aprocess used to separate) one or more constituents of a mixture. Forexample, in the exemplary embodiment described below, segregating mayinclude separating oxidizable catalyst from inert support media in amixture or a process where oxidizable catalyst is separated from inertsupport media, or vice versa. While some embodiments in this disclosureemploy screen devices for segregating, in the broadest sense, themethods of this disclosure are not limited to any particular segregationstructure. Alternative structures for separating materials by size orcomposition may be employed within the broad scope of this disclosure.

The term “inert gas,” as used herein, refers to a gas that does notundergo a chemical reaction under the prevailing conditions. As would berecognized by a person of ordinary skill in the art, inert gases mayinclude elemental gases, such as, for example, nitrogen and noble gases,or may include compound gases (i.e., a mixture of gases that does notundergo chemical reaction under prevailing conditions).

The systems and methods described herein may be provided on site at arefinery, in proximity to a refinery, in proximity to a remote wastetreatment or reclamation facility, or at a remote waste treatment orreclamation facility. Thus, while the present disclosure is not limitedto mobile segregation systems, in some disclosed embodiments,segregation systems may be mobile or may be constructed of componentsthat may be movable.

One example of a system for segregating a mixture of oxidizable catalystmaterial and inert support material may include segregation component100 b depicted in FIG. 1 . As described herein in greater detail, thesegregation component 100 b may include various components forsegregating a mixture of oxidizable catalyst material and inert supportmedia. In other embodiments, a system may include additional components,such as delivery component 100 a, an inert material collection container134 and one or more catalyst collection containers 136, 138 along withinterconnected conveyors, as is described later in greater detail.

Some disclosed embodiments may include an enclosure configured tocontain inert gas. One challenge in handling some oxidizable materialsis that they may become volatile when exposed to air. Thus, in someembodiments, segregation of inert support media and oxidizable catalystmaterial may occur in any container capable of receiving an inert gasand minimizing catalyst oxidation to an acceptable level (for example,to a level sufficient to reduce unacceptable risk). The container mayhave a lid, but need not have any particular form nor be made of anyparticular material, so long as it enables a sufficient amount of oxygenin the enclosure to be replaced by an inert gas while the segregation istaking place.

For example, in FIG. 1 , enclosure 108 of segregation component 100 bmay be a modified shipping container that is capable of beingtransported by a vehicle. Although not necessarily hermitically sealed,enclosure 108 may be designed to retain enough inert gas and/or excludeenough oxygen to enable a segregation process while minimizing the riskof setting off a dangerous catalyst oxidation reaction. In someembodiments, enclosure 108, may be provided with sealing material toenhance inert gas retention. Enclosure 108 may be pressurized using theinert gas. Inert gas 109 may be nitrogen or any other gas that does notinduce a chemical reaction (e.g., a volatile reaction) when exposed tothe mixture of catalyst and support media. Inert gas 109 may becontained in pressurized inert gas tank and may be fluidly coupled, orflow-connected, to the enclosure. In accordance with some embodiments,enclosure 108 may include one or more vents 118 for permitting gaswithin the enclosure to escape. Vents 118 may include openings, valves,filters, or any other mechanism suitable for allowing gas to escapeenclosure 108 while limiting introduction of ambient oxygen into theenclosure. Enclosure 108 may also include an observation window 132 inan outer wall thereof, and an illuminator 130 (e.g., a light, etc.) (seeFIG. 2 ) within the enclosure to enable external observation of themixture segregation, as illustrated in FIG. 2 . An observer may checkthe progress of the segregation process through the enclosure window ifdesired.

By way of one non-limiting example, FIG. 1 illustrates an exemplarysystem 100 for segregating a mixture of oxidizable catalyst material andinert support media. System 100 may include a delivery component 100 aand a segregation component 100 b. Delivery component 100 a may includeone or more flow bins 102 for containing the mixture of oxidizablecatalyst material and inert support media therein. A conveyor 104 maydeliver the mixture to segregation component 100 b. The conveyor 104,may be of any construction capable of moving material. For example, itmay include a belt conveyer, a slat conveyor, a troughed belt conveyor,a bucket conveyor, a screw conveyor, a vertical lift conveyor, acart-on-track conveyor, a tow conveyor, a trolley conveyor, a sortationconveyor or any other mechanism capable of moving material from onelocation to another. In some embodiments (not shown) where the deliverycomponent 100 a is located above segregation component 100 b, theconveyor may rely on gravity to feed segregation component 100 b. Insuch instances, the conveyor may simply be a chute or a conduit throughwhich the mixture flows by gravity. Alternatively, for example, a screwauger may be part of conveyor 104. In some embodiments, conveyor 104 maybe enclosed or otherwise sealingly engaged with flow bins 102 to limitexposure of the catalyst to oxygen as the catalyst travels from deliverycomponent 100 a to segregation component 100 b. Such limitation onoxygen exposure may be facilitated by a supply of inert gas to thesystem, as is described greater detail below.

In some embodiments, a mixture conveyor may include a controllable inletfor permitting selective passage of the mixture while limiting loss ofinert gas. For example, conveyor 104 may be selectively isolatable(either completely or partially) from the delivery component 100 a formaintaining an inert gas environment in a housing of conveyor 104. Agated inlet (not shown) may permit selective passage of the mixture intoconveyor 104 while limiting loss of the inert gas. The gate may beeither electronically or mechanically controlled so that when mixture isnot passing into conveyor 104, the gate is closed. If electronic, aprocessor may control both the conveyor and the gate so that the gateopens to deliver mixture to a moving conveyor and closes thereafter toenvironmentally isolate the delivery component 100 a from the conveyor104. It is to be understood that reference herein to environmentalisolation or an inert gas environment does not necessarily requirehermetic sealing. Rather, a goal may simply be to reduce oxygen levelsbelow a threshold level (for example, to below a level that poses anunacceptable risk of an adverse oxidation reaction).

With additional reference to FIG. 2 , segregation component 100 b mayinclude enclosure 108, screen assembly 110, inert support media conveyor114 and one or more catalyst material conveyors 116, 120. It is to beunderstood that the terms “inert support media conveyor” and “catalystmaterial conveyor” are illustrative and non-limiting. Conveyers 114,116, and 120 may be utilized to transport other non-hazardous orhazardous materials depending on the composition of the mixture to besegregated. For example, where the mixture includes topping incombination with inert support media and catalyst, conveyors 116 and/or120 may be utilized to transport both topping and catalyst. If forexample, the mixture consists of only hazardous materials (e.g. toppingand catalyst) one conveyor could be used to transport the larger of thehazardous components while one or more other conveyors could be used totransport the smaller hazardous components.

The entirety of segregation component 100 b or components thereof may beportable so as to facilitate relocation between industrial sites. Aninert gas inlet may be associated with the enclosure to permit the inertgas to enter the enclosure to displace oxygen within the enclosure tothereby limit oxidation of the oxidizable catalyst while the at leastone motor moves the plurality of stacked screens. Here, the term“associated with” means disposed on, in, in proximity to, or otherwisepositioned to enable inert gas to enter the enclosure. “Inlet” refers toany opening, valve, port or other construct for allowing inert gas toflow into the enclosure. By way of example with respect to FIG. 1 ,enclosure 108 may include an inert gas inlet 112 for receiving inert gas109. Inert gas inlet 112 may be located in a lower portion of theenclosure to enable the inert gas to flow over the catalyst material andexit the enclosure through a top portion of the enclosure. In this way,inert gas is permitted to blanket the catalyst and thereby limit therisk of oxidation.

Some disclosed embodiments may include a plurality of stacked screenswithin the enclosure, the stacked screens having openings that decreasein size from a top of the stack to a bottom of the stack. As usedherein, the term “screen” includes any structure with openings thereinthrough which material smaller than the sizes of the openings may pass.For example, a screen may have a lattice or woven structure, formed ofstrips, wire or any other material. A screen may include a surfaceperforated with holes. A series of spaced apart bars may constitute ascreen as may a sheet of metal, carbon fiber, or other material withopenings therethrough. Indeed, any surface regardless of shape orstructure may constitute a screen so long as it permits some sizes ofmaterials to pass through while retaining larger sized materials.

Screens are considered stacked if they assume an arrangement whereby onescreen is positioned above at least one other screen, regardless of thedistance between them. Typically, the distance between two stackedscreens should be at least sufficient to allow material on an upperscreen to pass through to a lower screen. Any number of screens mayconstitute a stack. The sizes of the openings in lower screens may besmaller than the size of the openings of upper screens. In this way,larger pieces of material may be retained on an upper screen, whilesmaller pieces fall through to a lower screen. Stacked screens may beparallel to one another, sloped, or combinations thereof.

Thus, a “screen” may include any porous or perforated stackablestructure capable of separating a material mixture into discretecomponents. In one embodiment, each screen may include a metallic meshhaving holes or openings, and a stack of screens may include screenswith holes or openings that decrease in size from a top of the stack toa bottom of the stack. The openings in the screens may have any shape orconfiguration (round, rectangular, square, etc.). For example, anuppermost screen of the stack (or a first screen) may define a pluralityof holes having a size (or diameter) D1, a second screen below the firstscreen may define a plurality of holes having a size (or diameter) D2,and a third screen below the second screen may define a plurality ofholes having a size (or diameter D3), such that D1>D2>D3. In general,any number of screens may be stacked together. In some embodiments, thenumber of screens in a stack may correspond to the number of differentlysized components to be segregated (e.g., three screens for threedifferently sized components). For example, if the mixture includesthree components to be segregated, D1 may be sized such that the largestof the three components is blocked by the first screen and the other twosmaller sized components are allowed to pass through to the secondscreen. A size D2 of the openings in the second screen may be such thatthe second largest component is blocked, thereby allowing the smallestcomponent to pass through to the third screen. Information relating tothe number of screens may be obtained in advance, e.g., based on theloading plan of the refinery, or determined on site. This configurationallows for the smaller sized hazardous components, e.g., catalyst andtopping material, to filter down through the stack and the larger inertsupport media to remain in a separate upper portion of the stack.Diameter D1 may be smaller than the size (e.g., diameter) of the inertsupport media, which may range in size, for example from 2 mm-2 in.,including: 2-4 mm, 5-7 mm, 9-11 mm, 11-13 m, 14-17 mm, 18-21 mm, 23-27mm, 36-40 mm, 46-50 mm, ⅛ in., ¼ in., ⅜ in., ½ in., 1 in., 1.5 in, and 2in.

By way of example, with reference to FIGS. 3A-3B, screen assembly 110includes a plurality of stacked screens 111 (including screens 111 a,111 b, etc.) configured to separate the inert support media from one ormore hazardous components. The hazardous components of the mixture aresmaller in diameter than the inert support material and therefore passthrough openings 113 a in screen 111 a and onto lower screen 111 b. Insome embodiments, screens 111 a and 111 b may be sloped to allowseparated inert and hazardous components to collect at the bottom oftheir corresponding screens. The screen assembly 110 may include a base121 on which the screens and their associated housing 123 are supported.A plurality of springs 119 may be disposed between the screen housing123 and the base 121 to absorb the shock of falling material and screenvibrations. Housing 123 may define sidewalls to which a motor 115 may beattached. In some embodiments, a sidewall may fully enclose a side ofthe housing 123, as illustrated for example in FIG. 3A. In someembodiments, the sidewall may only partially enclose a side of thehousing such that cleaning, maintenance, or adjustments to the screensmay be made through a side of the housing. A mixture of inert andhazardous material may enter screen assembly 110 through inlet 117 atthe top of the screen assembly 110 and fall onto the topmost screen ofthe plurality of stacked screens 111 (i.e., screen 111 a). Maintenanceand cleaning may also be performed through a port 125 at a top of thescreen assembly. It should be noted that although only one inlet 117 isillustrated in the figures, in some embodiments, multiple inlets may beprovided.

At least one inert support media outlet may be associated with at leastone of the plurality of stacked screens. The inert support media outletmay direct the separated inert support media to a location out of theenclosure. Here, the term “associated with” means positioned orotherwise oriented to permit inert support media to be transferred fromat least one of the stacked screens to a location outside of theenclosure. “Outlet” refers to any opening, conduit, hole, port, valve orother construct for allowing inert support media to be removed from thescreen. In some embodiments, the outlet may be formed on housing 123 ofscreen assembly 110. One or more outlets may be used to achieve thispurpose. In some embodiments, an air lock (not shown) may be associatedwith the inert support media outlet. The air lock may limit the amountof inert gas leaving the enclosure via the inert support media outlet.As used herein, “air lock” means any structure for restricting orcompletely preventing inert gas from leaving the enclosure. By way ofexample, FIG. 3A, illustrates an inert support media outlet 137 adisposed on an outer surface of housing 123. Outlet 137 a may bepositioned to intersect with support media that has collected at abottom of screen 111 a. Screen 111 a may be sloped toward outlet 137 asuch that inert support media at the intersection exits through outlet137 a. Although one outlet 137 a is depicted, in general, any number ofoutlets may be provided.

A catalyst material outlet may be associated with at least another ofthe plurality of stacked screens. The catalyst material outlet maydirect the separated oxidizable catalyst material to a location outsidethe enclosure. Here, the term “associated with” means positioned orotherwise oriented to permit oxidizable catalyst material to betransferred from another screen to a location outside of the enclosure.One or more outlets may be used to achieve this purpose. An air lock(not shown) may also be associated with the catalyst material outlet.The air lock may limit the amount of inert gas leaving the enclosure viathe catalyst material outlet. By way of example, catalyst materialoutlets 137 b and 137 c may be disposed on an outer surface of housing123. Outlets 137 b and 137 c may be positioned to intersect withoxidizable catalyst material that has collected at a bottom of screen111 b. Screen 111 b may be sloped toward outlets 137 b and 137 c suchthat oxidizable catalyst material at the intersection exits through theoutlet. Where topping is also incorporated in the mixture, topping mayalso collect at the intersection of outlet 137 b and 137 c beforeexiting therethrough.

To facilitate separation, at least one motor may be utilized for movingthe stacked screens to cause the oxidizable catalyst material toseparate from and migrate to a location beneath the inert support media.The motor may be electrical and operated remotely or directly, e.g., byswitch. The term “motor,” as used herein, may refer to any electricalmechanism for inducing vibration of the screens. The intensity and/orduration of the vibration may be adjusted to reflect the load of themixture. For example, stronger vibrations may be used to facilitateseparation of large mixture loads. Alternatively, vibration intensitymay remain constant, but for a longer duration to facilitate separation.The motor may be automated, such that the vibrations begin and/or end ata certain time or when the load on the screen reaches a predeterminedthreshold. By way of one non-limiting example, FIG. 3A illustrates amotor 115 disposed on a sidewall of the housing 123 of screen assembly110. One having ordinary skill in the art will understand that the motormay be placed at any of a variety of locations with respect to thescreen assembly, so long as its placement is sufficient to enablemovement of the screens and thus separation of the catalyst and supportmedia.

In accordance with some embodiments, inert support media conveyor 114may be secured to enclosure 108 via outlet 137 a such that it collectsthe separated inert support media. Although only one such conveyor isshown, it is to be understood that additional inert support mediaconveyors (and corresponding outlets) may be utilized to collect inertsupport media from screen assembly 110. Catalyst material conveyor 116may be secured to enclosure 108 via outlet 137 b and 137 c such that itcollects the separated catalyst material. Alternatively, outlets 137 band 137 c may each be secured to a catalyst material conveyor, asillustrated in FIG. 2 , to enable more rapid transport of the catalyst.Due to the smaller size of the catalyst material component, conveyor 116may be secured to a lower section of the enclosure corresponding to aposition of a bottom most screen; however, this configuration may bealtered depending on the size of the components to be separated.Conveyors 114 and 116 may also use screw elevation (or any of the meansdiscussed above with respect to conveyor 104) to transport the separatedcomponents out of the enclosure and to a desired location. Separatedinert support media may be transported, for example from conveyor 114 toreceptacle 134 for recycling or disposal, while separated catalystmaterial may be transported to another receptacle 136 for reclamation,regeneration or landfill disposal as illustrated in FIG. 1 .

In some embodiments, system 100 may include one or more sensors fordetecting a reduction of oxygen in the enclosure and a regulator for atleast periodically supplying additional inert gas to the enclosure toaccount for loss of the inert gas. As used herein, “sensor” means anydevice, module, machine, or system for directly or indirectly measuring,detecting, sensing, recording or storing oxygen concentration. Thesensor may be located on an outer surface of the enclosure, within theenclosure, or at any other locale suitable for measuring, detecting,recording or storing the concentration of oxygen within the enclosure.Where the sensor is located within the enclosure, an observer may checka measurement of the sensor, via, e.g., window 132. The regulator may bemanually operated by an observer or automated to supply inert gas whenthe level of inert gas within the enclosure falls below a predeterminedthreshold. In some embodiments, the sensor measures, detects, recordsand/or stores an oxygen concentration within the enclosure and signalsthe regulator to begin or stop supplying inert gas depending on themeasured oxygen concentration. In this way, the sensor and regulatorwork together to automatically monitor and manage the level of oxygen inthe enclosure. By way of example, FIG. 1 depicts a regulator 126disposed on an outer surface of the enclosure and a sensor 128 on a topof surface of the enclosure.

System 100 may also include a grinder for grinding the separatedoxidizable catalyst material into a powder. In accordance with someembodiments, the grinder may be located in a region supplied with theinert gas, including, by way of example, the inside of the enclosure.The grinder may also be stationed at a remote location so long as thecatalyst is supplied with inert gas to prevent the pulverized catalystfrom oxidizing. The grinder may include an inlet for receiving catalystfrom a catalyst conveyer. A ground catalyst conveyor may be associatedwith the grinder for transporting ground catalyst from the grinder fordisposal.

By way of non-limiting example, FIG. 2 illustrates a catalyst conveyor120, grinder 122, and ground catalyst conveyor 124. Catalyst conveyor120 may be configured to transport catalyst from screen assembly 110 togrinder 122. In some embodiments, catalyst conveyor 120 may be connectedto screen assembly 110 at, for example outlet 137 d. Outlet 137 d mayreceive catalyst from a lower-most screen of screen assembly 110 ordirectly from an accumulation of catalyst particles at the bottom ofhousing 123. Ground catalyst may be transported via ground catalystconveyor 124 to a bin or other receptacle 138 for disposal via, e.g.,incineration.

It is to be understood that the system may use one or both catalystconveyors 116, 120 to dispose of catalyst. When both are in use,segregated catalyst particles of a first size may be transported fordisposal via catalyst conveyor 116 while segregated catalyst particlesof a second, smaller size maybe transported for disposal via catalystconveyor 120. Further still, if the mixture contains topping in additionto the catalyst and inert support media, catalyst conveyor 116 may beused to transport topping while catalyst conveyor 120 may be used totransport catalyst.

A method for disposing of a mixture of oxidizable catalyst material andinert support media will now be discussed with respect to the exemplarymethod illustrated in FIG. 4 .

Beginning at step 400, inert gas is introduced into an enclosure. Asdiscussed above, the enclosure may contain a plurality of stackedscreens, each stacked screen having openings that decrease in size froma top of the stack to a bottom of the stack. The inert gas may benitrogen and enter the enclosure 108 via inert gas inlet 112. Prior toor during this time, one or more flow bins 102 may be filled with amixture of oxidizable catalyst material and inert support media.Enclosure 108 may be pressurized using the inert gas so as to displaceoxygen within the enclosure.

At step 402, the mixture is introduced to an uppermost one of theplurality of stacked screens. The mixture may be transported directlyfrom one or more flow bins 102 to the enclosure using, e.g., a gravitydump, or indirectly through conveyor 104 and into inlet 117 of screenassembly 110, where it drops onto uppermost screen 111 a.

At step 404, the plurality of stacked screens are moved to cause theoxidizable catalyst material to separate from and migrate to a locationbeneath the inert support media. Motor 115 may be used to move thescreens and thereby facilitate separation. The intensity and/or durationof the movement may be adjusted to reflect the load of the mixture; withlonger durations and/or stronger movement being used to separate largerquantities of mixture.

Since the openings of adjacent screens, e.g., openings 113 a, 113 b ofscreens 111 a, 111 b, decrease in size from a top of the stack to abottom of the stack, this movement causes the smaller catalyst materialcomponents to filter down through the stack while the larger inertsupport media component remains in a separate upper portion of thestack. Inert support media on uppermost screen 11 a may collect at thebottom of the screen where the screen intersects with outlet 137 a,while separated catalyst material at a bottom of the stack, for exampleon screen 111 b, may collect where the screen intersects outlets 137 band 137 c. It is to be understood that the mixture may alternatively bedeposited onto a lower screen, e.g., a second or third highest screen,so long as a sufficient number of screens are utilized to enableseparation of the differently sized mixture components.

At step 406, the separated inert support media may be conveyed to alocation outside the enclosure for recycling or disposal asnon-hazardous waste. Separated inert support media may collect at abottom of screen 111 a, then directed through outlet 137 a, and intoinert support media conveyor 114. Inert support media conveyor 114 maytransport the separated inert support media to receptacle 134, afterwhich it may be disposed of or repurposed as desired.

At step 408, separated oxidizable catalyst material may be conveyed to alocation outside the enclosure for at least one of reclamation orthermal destruction. Separated oxidizable catalyst material may bedirected to any one of outlets 137 b, 137 c and/or 137 d. Where, forexample, separated catalyst material is routed through outlets 137 band/or 137 c, catalyst conveyor 116 may transport the separated catalystto a receptacle 136 for reclamation and/or thermal destruction. Ifseparated catalyst material is routed through outlet 137 d, the catalystmay be ground as described in detail with respect to FIG. 5 .

A method of disposing of a mixture of oxidizable catalyst material andinert support media will now be discussed with respect to the exemplarymethod illustrated in FIG. 5 .

Beginning at step 500, inert gas is introduced into an enclosure. Asdiscussed above, the enclosure may contain a plurality of stackedscreens, each stacked screen having openings that decrease in size froma top of the stack to a bottom of the stack. The inert gas may benitrogen and enter the enclosure 108 via inert gas inlet 112. Prior toor during this time, one or more flow bins 102 may be filled with amixture of oxidizable catalyst material and inert support media.Enclosure 108 may be pressurized using the inert gas so as to displaceoxygen within the enclosure.

At step 502, the mixture is introduced into the enclosure. As describedabove with respect to 402, the mixture may be introduced into the screenassembly via inlet 117 and onto an uppermost one of the plurality ofstacked screens. The mixture may be transported directly from one ormore flow bins 102 to the enclosure using, e.g., a gravity dump, orindirectly through conveyors 104 and 106.

At step 504, the oxidizable catalyst material and the inert supportmedia within the enclosure are separated. As with step 404, theplurality of stacked screens are moved to cause the oxidizable catalystmaterial to separate from and migrate to a location beneath the inertsupport media. Motor 115 may be used to move the screens and therebyfacilitate separation. The intensity and/or duration of the movement maybe adjusted to reflect the load of the mixture; with longer durationsand/or stronger movement being used to separate larger quantities ofmixture.

Since the openings of adjacent screens, e.g., openings 113 a, 113 b ofscreens 111 a, 111 b, decrease in size from a top of the stack to abottom of the stack, this movement causes the smaller catalyst materialcomponents to filter down through the stack while the larger inertsupport media component remains in a separate upper portion of thestack. Inert support media on uppermost screen 111 a may collect at thebottom of the screen where the screen intersects with outlet 137 a whileseparated catalyst material at a bottom of the stack, for example onscreen 111 b, may collect where the screen intersects outlets 137 b and137 c. It is to be understood that the mixture may alternatively bedeposited onto a lower screen, e.g., a second or third highest screen,so long as a sufficient number of screens are utilized to enableseparation of the differently sized mixture components.

At step 506, an inert gas environment is maintained around theoxidizable catalyst material during separating. A sensor for detecting areduction of oxygen in the enclosure and a regulator for at leastperiodically supplying additional inert gas to the enclosure, may beused to maintain the inert gas environment. The regulator may bemanually operated by an observer or automated to supply inert gas whenthe level of inert gas within the enclosure falls below a predeterminedthreshold. The sensor may measure an oxygen concentration within theenclosure and signal the regulator to begin or stop supplying inert gasdepending on the measured oxygen concentration. In this way, the sensorand regulator work together to automatically monitor and manage thelevel of oxygen in the enclosure.

At step 508, the separated inert support media is exported from theenclosure. As with step 406, the separated inert support media may beconveyed to a location outside the enclosure for recycling or disposalas non-hazardous waste. Separated inert support media may collect at abottom of screen 11 a, where it is then directed through outlet 137 a,and into inert support media conveyor 114. Inert support media conveyor114 may transport the separated inert support media to receptacle 134,after which it may be disposed of or repurposed as desired.

At step 510, the separated oxidizable catalyst material is ground into apowder for disposal as hazardous waste via incineration. Separatedcatalyst material is routed through outlet 137 d, which is connected tocatalyst conveyor 120. Catalyst conveyor 120 transports the separatedcatalyst to a grinder 122. Once ground, the ground catalyst may betransported via ground catalyst conveyor 124 to a receptacle 138 forreclamation and/or thermal destruction. The receptacle may be secured toa vehicle for immediate transportation as illustrated in FIG. 1 orloaded onto a vehicle at a later time.

A method of disposing of a mixture of oxidizable catalyst material andinert support media will now be discussed with respect to the exemplarymethod illustrated in FIG. 6 .

Beginning at step 600, inert gas is introduced into an enclosure. Asdiscussed above, the enclosure may contain a plurality of stackedscreens, each stacked screen having openings that decrease in size froma top of the stack to a bottom of the stack. The inert gas may benitrogen and enter the enclosure 108 via inert gas inlet 112. Prior toor during this time, one or more flow bins 102 may be filled with amixture of oxidizable catalyst material and inert support media.Enclosure 108 may be pressurized using the inert gas so as to displaceoxygen within the enclosure.

At step 602, a mixture of oxidizable catalyst material, grading materialand inert support media are introduced into the enclosure. The mixturemay be introduced into the screen assembly via inlet 117 and onto anuppermost one of the plurality of stacked screens. The mixture may betransported directly from one or more flow bins 102 to the enclosureusing, e.g., a gravity dump, or indirectly through conveyor 104.

At step 604, the oxidizable catalyst material, grading material and theinert support media within the enclosure are separated. As discussedabove with respect to FIGS. 4 and 5 , the plurality of stacked screensare moved, using, e.g., motor 115, to facilitate separation. Theintensity and/or duration of the movement may be adjusted to reflect theload of the mixture; with longer durations and/or stronger movementbeing used to separate larger quantities of mixture.

Since the openings of adjacent screens, e.g., openings 113 a, 113 b ofscreens 111 a, 111 b, decrease in size from a top of the stack to abottom of the stack, this movement causes the smaller grading andcatalyst material components to filter down through the stack while thelarger inert support media component remains in a separate upper portionof the stack. Inert support media on uppermost screen 111 a may collectat the bottom of the screen where the screen intersects with outlet 137a, while separated catalyst and grading material at a bottom of thestack, for example on screen 111 b, may collect where the screenintersects outlets 137 b and 137 c. If the grading and catalystmaterials differ in size, a third screen may be utilized. In this case,the smaller, e.g., catalyst material will be permitted to filter throughthe second screen and onto the third screen. Alternatively, the smallercatalyst may be permitted to accumulate at a bottom of the screener, inwhich case an additional screen is not needed.

At step 606, an inert gas environment is maintained around theoxidizable catalyst material during separating. A sensor for detecting areduction of oxygen in the enclosure and a regulator for at leastperiodically supplying additional inert gas to the enclosure, may beused to maintain the inert gas environment. The regulator may bemanually operated by an observer or automated to supply inert gas whenthe level of inert gas within the enclosure falls below a predeterminedthreshold. The sensor may measure an oxygen concentration within theenclosure and signal the regulator to begin or stop supplying inert gasdepending on the measured oxygen concentration. In this way, the sensorand regulator work together to automatically monitor and manage thelevel of oxygen in the enclosure.

At step 608, the separated inert support media is exported from theenclosure. As with step 406, the separated inert support media may beconveyed to a location outside the enclosure for disposal asnon-hazardous waste. Separated inert support media may collect at abottom of screen 111 a, where it is then directed through outlet 137 a,and into inert support media conveyor 114. Inert support media conveyor114 may transport the separated inert support media to receptacle 134,after which it may be disposed of or repurposed as desired.

At step 610, grading material is conveyed to a location outside theenclosure. The separated material may be directed to outlet 137 b and/or137 c and transported outside of enclosure 108 via conveyor 116 and intoreceptacle 136 for collection.

At step 612, separated oxidizable catalyst material is conveyed to alocation outside the enclosure. Separated oxidizable catalyst materialmay be directed to any one of outlets 137 b, 137 c and/or 137 d. Where,for example, separated catalyst material is routed through outlets 137 band/or 137 c, catalyst conveyor 116 may transport the separated catalystto receptacle 136. In some cases, the catalyst may be comingled with thegrading material disposed of at step 610. If the catalyst material isrouted through outlet 137 d (for example, after passing through thesecond screen and onto a third screen or a bottom of the screeningassembly as discussed above in step 604), the separated oxidizablecatalyst material may ground into a powder for disposal as hazardouswaste via incineration. Catalyst conveyor 120 transports the separatedcatalyst to a grinder 122. Once ground, the ground catalyst may betransported via ground catalyst conveyor 124 to a receptacle 138 forreclamation, regeneration and/or landfill disposal. The receptacle maybe secured to a vehicle for immediate transportation as illustrated inFIG. 1 or loaded onto a vehicle at a later time.

Disclosed embodiments may include any one of the followingbullet-pointed features alone or in combination with one or more otherbullet-pointed features, whether implemented in connection with adevice, a system, or a method:

-   -   a system for segregating a mixture of oxidizable catalyst        material and inert support media    -   an enclosure configured to contain inert gas    -   a plurality of stacked screens within the enclosure, the stacked        screens having openings that decrease in size from a top of the        stack to a bottom of the stack    -   a mixture inlet in the enclosure positioned to enable delivery        of the mixture to an uppermost stacked screen    -   at least one inert support media outlet associated with at least        one of the plurality of stacked screens, wherein the at least        one inert support media outlet directs separated inert support        media to a location out of the enclosure    -   a catalyst material outlet associated with at least another of        the plurality of stacked screens, wherein the catalyst material        outlet directs separated oxidizable catalyst material to a        location outside the enclosure    -   at least one motor for moving the stacked screens to cause the        oxidizable catalyst material in the mixture to separate from and        migrate to a location beneath the inert support media    -   an inert gas inlet associated with the enclosure for permitting        the inert gas to enter the enclosure to displace oxygen within        the enclosure and thereby limit oxidation of the oxidizable        catalyst material while the at least one motor moves the        plurality of stacked screens    -   wherein the enclosure is configured for pressurization of the        inert gas    -   wherein the inert gas inlet is located in a lower portion of the        enclosure to enable the inert gas to flow over the oxidizable        catalyst material and exit the enclosure through a top portion        of the enclosure    -   a sensor for detecting a reduction of oxygen in the enclosure    -   a mixture conveyor for conveying the mixture to the mixture        inlet, wherein the mixture conveyor is in flow communication        with the enclosure and is enclosed to contain the inert gas    -   at least one flow bin associated with an end of the mixture        conveyor for supplying the mixture to the mixture conveyor,        wherein the mixture conveyor is sealingly engaged with the flow        bin and the enclosure to contain the inert gas    -   wherein the mixture conveyor includes a screw auger    -   wherein the mixture conveyor includes a controllable inlet for        permitting selective passage of the mixture while limiting loss        of the inert gas    -   a regulator for at least periodically supplying additional inert        gas to the enclosure to account for loss of the inert gas    -   an air lock associated with the inert support media outlet for        limiting the inert gas from leaving the enclosure via the inert        support media outlet    -   an air lock associated with the catalyst material outlet for        limiting the inert gas from leaving the enclosure via the        catalyst material outlet    -   a pressurized inert gas tank flow-connected to the enclosure    -   wherein the enclosure and plurality of stacked screens are        configured as a portable unit for movement between industrial        sites    -   a grinder for grinding the separated oxidizable catalyst        material into a powder    -   wherein the grinder is located in a region supplied with the        inert gas    -   wherein the grinder is contained within the enclosure and the        mixture inlet is a hazardous waste inlet    -   an observation window in an outer wall of the enclosure, and an        illuminator within the enclosure to enable external observation        of the mixture segregation    -   wherein the inert gas tank contains nitrogen    -   a method for disposing of a mixture of oxidizable catalyst        material and inert support media    -   introducing inert gas into an enclosure, wherein the enclosure        contains a plurality of stacked screens, the stacked screens        having openings that decrease in size from a top of the stack to        a bottom of the stack    -   introducing the mixture to an uppermost one of the plurality of        stacked screens    -   moving the plurality of stacked screens to cause the oxidizable        catalyst material to separate from and migrate to a location        beneath the inert support media    -   conveying the separated inert support media to a location        outside the enclosure for disposal as non-hazardous waste    -   conveying the separated oxidizable catalyst material to a        location outside the enclosure for at least one of reclamation        or thermal destruction    -   wherein the thermal destruction includes disposal via        incineration    -   wherein the inert gas is nitrogen    -   wherein introducing the mixture includes conveying the mixture        in a closed conveyor containing the inert gas    -   wherein conveying the separated oxidizable catalyst material to        a location outside the enclosure includes conveying the        separated oxidizable catalyst material in a closed conveyor        containing the inert gas    -   incinerating the separated oxidizable catalyst material in a        cement kiln    -   storing the separated oxidizable catalyst material for reuse in        an industrial process    -   storing the separated inert media for reuse in an industrial        process    -   wherein conveying the separated oxidizable catalyst material and        inert support media to a location outside the enclosure includes        using a screw auger    -   sensing oxygen presence within the enclosure    -   wherein the enclosure maintains an inert gas environment around        the oxidizable catalyst    -   a method of disposing of a mixture of oxidizable catalyst        material and inert support media    -   introducing inert gas into an enclosure    -   introducing the mixture into the enclosure    -   separating the oxidizable catalyst material and the inert        support media within the enclosure    -   maintaining an inert gas environment around the oxidizable        catalyst material during separating    -   exporting the separated inert support media from the enclosure    -   grinding the separated oxidizable catalyst material into a        powder for disposal as hazardous waste via incineration    -   wherein the grinding occurs in an inert gas environment    -   wherein introducing the mixture into the enclosure includes        removing the mixture from a refinement container and        transferring the mixture to the enclosure via a conveyor    -   wherein the inert gas is nitrogen    -   wherein the separated oxidizable catalyst material is ground        into a powder for suspension in a liquid fuel for a cement kiln    -   wherein the enclosure is movable and wherein the method further        includes moving the enclosure to an industrial site    -   wherein the mixture further comprises grading material; and        separating the grading material from the inert support media    -   exporting the grading material from the enclosure    -   wherein the grading material is exported with the oxidizable        catalyst material    -   wherein the grading material is exported separately from the        oxidizable catalyst material

Although system 100 is described as being used to separate refinerywaste (e.g., inert material from catalyst) in a mixture, as explainedpreviously, this is only exemplary. In general, the systems and methodsof the current disclosure may be used to separate or segregate theconstituent components of a mixture in any application. Whileillustrative embodiments have been described herein, the scope of anyand all embodiments having equivalent elements, modifications,omissions, combinations (e.g., of aspects across various embodiments),adaptations and/or alterations as would be appreciated by those skilledin the art based on the present disclosure. The limitations in theclaims are to be interpreted broadly based on the language employed inthe claims and not limited to examples described in the presentspecification or during the prosecution of the application. The examplesare to be construed as non-exclusive. Furthermore, the steps of thedisclosed methods may be modified in any manner, including by reorderingsteps and/or inserting or deleting steps. It is intended, therefore,that the specification and examples be considered as illustrative only,with a true scope and spirit being indicated by the following claims andtheir full scope of equivalents.

1. A system for segregating a mixture of oxidizable catalyst materialand inert support media, the system comprising: an enclosure configuredto contain inert gas; a plurality of stacked screens within theenclosure, the stacked screens having openings that decrease in sizefrom a top of the stack to a bottom of the stack; a mixture inlet in theenclosure positioned to enable delivery of the mixture to an uppermoststacked screen; at least one inert support media outlet associated withat least one of the plurality of stacked screens, wherein the at leastone inert support media outlet directs separated inert support media toa location out of the enclosure; a catalyst material outlet associatedwith at least another of the plurality of stacked screens, wherein thecatalyst material outlet directs separated oxidizable catalyst materialto a location outside the enclosure; at least one motor for moving thestacked screens to cause the oxidizable catalyst material in the mixtureto separate from and migrate to a location beneath the inert supportmedia; and an inert gas inlet associated with the enclosure forpermitting the inert gas to enter the enclosure to displace oxygenwithin the enclosure and thereby limit oxidation of the oxidizablecatalyst material while the at least one motor moves the plurality ofstacked screens, wherein the inert gas inlet is located in a lowerportion of the enclosure to enable the inert gas to flow over theoxidizable catalyst material and exit the enclosure through a topportion of the enclosure.
 2. The system of claim 1, wherein theenclosure is configured for pressurization of the inert gas. 3.(canceled)
 4. The system of claim 1 further comprising a sensor fordetecting a reduction of oxygen in the enclosure.
 5. The system of claim1, further comprising a mixture conveyor for conveying the mixture tothe mixture inlet, wherein the mixture conveyor is in flow communicationwith the enclosure and is enclosed to contain the inert gas.
 6. Thesystem of claim 5, further comprising at least one flow bin associatedwith an end of the mixture conveyor for supplying the mixture to themixture conveyor, wherein the mixture conveyor is sealingly engaged withthe flow bin and the enclosure to contain the inert gas.
 7. The systemof claim 6, wherein the mixture conveyor includes a screw auger.
 8. Thesystem of claim 5, wherein the mixture conveyor includes a controllableinlet for permitting selective passage of the mixture while limitingloss of the inert gas.
 9. The system of claim 1, further comprising aregulator for at least periodically supplying additional inert gas tothe enclosure to account for loss of the inert gas.
 10. The system ofclaim 1, further comprising an air lock associated with the inertsupport media outlet for limiting the inert gas from leaving theenclosure via the inert support media outlet.
 11. The system of claim 1,further comprising an air lock associated with the catalyst materialoutlet for limiting the inert gas from leaving the enclosure via thecatalyst material outlet.
 12. The system of claim 1, further comprisinga pressurized inert gas tank flow-connected to the enclosure.
 13. Thesystem of claim 1, wherein the enclosure and plurality of stackedscreens are configured as a portable unit for movement betweenindustrial sites.
 14. The system of claim 1, further comprising agrinder for grinding the separated oxidizable catalyst material into apowder.
 15. The system of claim 14, wherein the grinder is located in aregion supplied with the inert gas.
 16. The system of claim 15, whereinthe grinder is contained within the enclosure and the mixture inlet is ahazardous waste inlet.
 17. The system of claim 1, further comprising anobservation window in an outer wall of the enclosure, and an illuminatorwithin the enclosure to enable external observation of the mixturesegregation.
 18. The system of claim 12, wherein the inert gas tankcontains nitrogen.